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My preference is to weld and remachine over anything else. My experience mirrors Ned's with fitting stainless - no force-fit and lapping, instead machine it to a very close but free running fit and keep it lubed with a light grease.
Thank you to everyone that has responded to this thread. This board is an excellent resource.
John, on the weld and remachine approach do you weld with regular carbon steel rod as opposed to stainless rod? In other words are the contact points on the rails effectively changed from stainless to carbon steel and as a result a much tighter fit available, or is it still stainless on stainless and somewhat loser.
I personally prefer the weld build up be done with carbon steel, but will do it either way, if the client has a preference. I don't think there is an appreciable difference in the end result of the tightness of fit whichever way you do it. The reason I'd rather use carbon wire is that if the parts run bone-dry, stainless on stainless (I don't care what alloy it is) will gall quicker than if carbon is in the mix.
The feel of a gun that you perceive as being really tight is in reality a gun that has a higher friction fit caused by either extra engagement surface being felt (like Acc-U-Rails) or being so snugly fit that the lube is being scraped off the fitted surfaces as they run. I believe you're better off in the long run to have a fit that has .001" or so clearance, so the lube doesn't scrape off, the gun runs freely and that fit will stay the same for a very long time. In battery, there's no play to feel as all fitting points are direct bearing and clearances are zero, but when it unlocks, nothing drags as it runs.
Said another way, I prefer the bare slide to move freely from it's own weight when mounted on the bare frame and tilted at 45 degrees, yet have no play that you can feel, with a light film of oil on the rails.
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